Cohesive vegetable products and process for manufacture

ABSTRACT

Powdered grain and/or legume material is mixed with a liquid binder containing algin to form a dough that is molded, or extruded and the extruded material severed, to form synthesized kernels or bits. Such kernels or bits are deposited in an edible boiling liquid, preferably containing calcium chloride and/or calcium lactate, for setting the binder, and cooked in such setting liquid for a few minutes after which they are removed from the setting or gelling liquid, rinsed, retrograded, or set and stabilized in their cooked and expanded state as by freezing or the like, and dried; or they may be canned or frozen. As a consequence, the kernels or bits can be rehydrated and rendered instantly edible merely by the addition of an edible hot or cold liquid without requiring further cooking. The bits may contain other food ingredients and/or fortifying agents such, merely by way of example, as vitamins, minerals, proteins, amino acids, fats, oils, medicaments and/or flavorings or coloring materials.

RELATION TO OTHER APPLICATIONS

This application is a continuation-in-part of application Ser. No.07/369,633 filed 21 Feb. 1989 for COHESIVE VEGETABLE PRODUCTS ANDPROCESS FOR MANUFACTURE now abandoned. That application is a division ofSer. No. 07/105,293 filed 11 Sep. 1987 for COHESIVE VEGETABLE PRODUCTSAND PROCESS FOR MANUFACTURE (now U.S. Pat. No. 4,844,936). Thatapplication is a continuation-in-part of Applicants' copendingapplication Ser. No. 06/930,585 filed 13 Nov. 1986 and entitled COHESIVEPOWDER BIT VEGETABLE PRODUCTS AND PROCESS FOR MAKING THE SAME (nowabandoned).

Applicants' application Ser. No. 06/930,585 is a continuation-in-part ofapplication Ser. No. 06/885,624 filed 19 Jun. 1986 and designated inPatent Cooperation Treaty application PCT/US85/01746 filed 11 Sep. 1985and claiming priority from Applicants' U.S. application Ser. No.06/649,444 filed 11 Sep. 1984 (now abandoned). The two applicationsidentified in this paragraph are both entitled SYNTHESIZED KERNEL GRAINOR LEGUMES.

TECHNICAL FIELD OF THE INVENTION

The present invention relates to a cohesive powder kernel or bit productcomposed of kernels or bits that have been formed from meal or flour ofvegetables including seeds of cereals and/or seeds of pulses and/orleaves of leafy vegetables and/or stalk vegetables and/or rootvegetables, which kernels or bits can be composed of a single variety ofvegetable product or can incorporate products of more than one varietyof vegetable and can include other types of food and/or edible material,yet which can be rehydrated and rendered instantly edible, withoutfurther cooking, merely by the addition of an edible liquid, either hotor cold.

BACKGROUND OF THE INVENTION

The prior art is replete with patents relating to the formation of awide range of food products from seed grains and/or other vegetablematerials. Two of such prior art patents expressly disclose processesfor preparing what are said to be quick-cooking rice products frombroken grains of rice--viz., Gorozpe U.S. Pat. Nos. 2,914,005 and3,071,471. The disclosures in the Gorozpe patents are more fullydescribed in the aforesaid Related Applications and need not be furtherdescribed herein. Suffice it to say that other than the concept ofattempting to form a quick-cooking rice product from broken rice grains,the process steps employed by Gorozpe and the resulting food productbear no similarities to those of the present invention.

Another known prior art patent more fully described in the aforesaidRelated Applications is Harrow et al. U.S. Pat. No. 4,325,971--a patentwhich discloses a process for making a reformed rice product from flourwhich can include wheat flour, potato flour, corn flour, tapioca flour,waxy maize flour, and rice flour; but, it is preferred that at least amajor portion of the flour be rice flour.

However, none of the foregoing prior art patents disclose a process inwhich alginate or other binder material in conjunction with a setting orgelling agent is combined with vegetable meal or flour to impart to suchmeal or flour a cohesive quality in the production of a powder kernelvegetable product; but, Willock U.S. Pat. No. 3,365,299 does propose theuse of a seaweed gum or alginate mucilage coating for rice grains inproducing a rice pudding.

Kamada et al. U.S. Pat. No. 4,101,683 discloses the use of alginateamong other polysaccharides in connection with puffed rice. The processof this patent gelatinizes the rice starch by first puffing rice grainsto a high degree. Such puffing and gelatinizing is accomplished byheating the rice grains in a closed container at an elevated temperatureunder increased pressure and releasing the rice grains into theatmosphere to allow them to puff, or heating the rice grains by means ofheated air or by high frequency waves. Thereafter, a thickener is addedto the puffed rice grains, which thickener may be polysaccharide,including agar and alginate, or gums including guar gum, or artificiallyproduced thickeners, or microorganically produced thickeners. Thethickener is applied to the puffed rice by immersing the puffed rice inan aqueous solution containing the thickener, or by spraying orsprinkling the aqueous solution on the puffed rice. Finally, the puffedrice, with which the thickener has been incorporated, is dried eitherunder normal atmospheric pressure or under vacuum, either in thepresence or in the absence of heating. In consequence of the gradualvaporization of water, the puffed rice diminishes in volume, eventuallyapproaching the volume of raw rice. It is said that the resulting ricewill be fast cooking in one to two minutes in hot water heated inadvance to about 80° C. The rice can even be rehydrated at roomtemperature by being soaked in water for about 30 minutes.

While the process described in Kamada et al. U.S. Pat. No. 4,101,683does not utilize any setting agent, the use of such an agent isdisclosed in Kamada et al. U.S. Pat. No. 4,085,234. This patentdiscloses a rice product made by puffing rice to a high degree by firsttreating the rice grains in a closed container kept at an elevatedtemperature and releasing the rice grains into the atmosphere, therebyallowing them to puff to a degree from 6 to 16 times, and preferably 10to 12 times, as large as the raw rice grains. The puffed rice grains arethen immersed in, or sprayed or sprinkled with, an aqueous solutioncontaining at least one polysaccharide thickener which is gelledmetallic ions. Examples of such polysaccharides are alginic acid, itssalt, carrageen, pectin, etc.

As in Kamada et al. U.S. Pat. No. 4,101,683, the puffing step of thispatent, Kamada et al. U.S. Pat. No. 4,085,234, gelatinizes the ricestarch. The puffing may expand the rice grains to a volume from sixtimes as large as normal rice grains to as much as 15 times as large asordinary rice grains. Also, a thickener such as sodium alginate can beapplied externally on the puffed rice grains by immersing the puffedrice grains in a thickener solution, or by spraying the thickener ontothe rice grains. After the thickener has been incorporated in the puffedrice grains, the treated puffed rice is immersed in an aqueous solutioncontaining metallic ions capable of inducing gelation of the thickener;or, alternatively, such a solution is sprayed or sprinkled on the puffedrice. The expression "aqueous solution containing metallic ions"includes aqueous solutions prepared by addition of metallic salts,solutions prepared by an ion exchange treatment, naturally occurringmineral waters containing metallic ions, and natural aqueous solutionswhich originate in animals and plants. Various metallic salts aredescribed in the Kamada et al. patents, including calcium salts,potassium salts, magnesium salts, and other similar metallic salts ofcarbonic acid, hydrochloric acid, sulfuric acid, phosphoric acid, aceticacid, lactic acid, citric acid, ascorbic acid, glycerophosphoric acid,and other similar acids. The metallic ions are stated to be capable ofacting upon the thickener to be gelled and consequently inducinggelation. A specific example is the combination of sodium alginate andcalcium lactate. Another example is a low methyl ester pectin andcalcium chloride. A further example uses the combination of sodiumalginate and calcium lactate. Another example proposes the combinationof calcium and potassium-sensitive carrageenin and calcium lactate.

After the rice has been treated with the thickener and the metallicsalt, the puffed rice into which the thickener or the gelled thickenerhas been incorporated is dried under normal atmospheric pressure orunder vacuum either in the absence or in the presence of heating toproduce a fast-cooking rice. During the drying step, the puffed ricediminishes in volume to approach the volume of raw rice, while theincorporated gelled thickener is retained throughout from the surface tothe inside center of the individual grains.

SUMMARY OF THE INVENTION

Improved synthesized cohesive vegetable products which can be rehydratedand rendered instantly edible, without further cooking, merely by theaddition of a hot or cold edible liquid, are formed in accordance withthe present invention by: i) grinding, crushing or otherwise pulverizingor comminuting vegetable material including grain seeds which may bedefective, such as being broken, cracked, or misshapen; ii) mixing themeal or powder with water and a settable binder to impart to it acohesive paste-like doughy quality; iii) forming the cohesive paste-likepowder mixture into reconstituted or synthesized powder kernel shapes orbits, such as by compression die molding of the cohesive paste-likepowder or by extruding the cohesive paste-like powder in dough form intostrings and cutting these strings into reconstituted or synthesizedkernels or bits; iv) heating, and preferably gelatinizing, thereconstituted or synthesized kernels or bits by, for example, depositingsuch kernels or bits in boiling water containing a suitable metallicsalt setting agent and cooking such kernels or bits until expanded; v)rinsing the expanded kernels or bits so as to remove excess settingagent and cool the kernels o bits; vi) retrograding the expanded kernelsor bits by, for example, freezing to set the product in its expandedstate; and vii) drying the retrograded kernels or bits to reduce theirmoisture content to on the order of approximately 9-12 percent moisturecontent by weight with a moisture content in the range of 9.5 to 10.5percent being preferred. Higher moisture contents than those justidentified are avoided because the product would, at best, have only avery short, unacceptable shelf life. Drying the product to a level lowerthan those indicated robs the product of water of hydration. This isunacceptable as the product loses strength, becomes friable and chalky,and is apt to check when it is extruded.

Because the vegetable matter is ground, crushed, or otherwise pulverizedor comminuted in the initial step of the process, it becomes possible toadd any selected fortifying agent to the ingredients which form thebatter. Thus, for example, it is entirely possible to fortify theproduct by adding any one or more of fortifying agents selected from thegroup consisting of: a) vitamins; b) minerals; c) proteins; d) aminoacids; e) fats; f) oils; g) medicaments; and h) flavorings. Thus, thefinished product, if fortified, is not only capable of being rehydratedand rendered instantly edible merely by the addition of a hot or coldedible liquid; but, additionally, it can provide all or any selectedportion of the daily dietary requirements for human beings.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a diagrammatic representation of portions of an apparatussuitable for performing certain steps of a process according to thepresent invention to produce products according to the presentinvention.

DETAILED DESCRIPTION OF THE INVENTION

In this description, the term powder kernel or bit is used to designatedkernels or bits synthesized from powder including a binder.Reconstituted kernels may simulate whole natural cereal seeds such as ofrice, wheat, oats, millet, corn, rye, and barley, or pulse seeds such asof peanuts, peas, and beans including kidney beans, lima beans, lentils,and soy beans. Synthesized bits can be produced from legumes or leafyplants such as of vetch, alfalfa, clover, spinach, and pea pods, orstalk vegetables such as corn, tomatoes and green peppers, or rootvegetables such as carrots, turnips, beets, onions, and potatoes.Special combination synthesized kernels, which may or may not simulatewhole natural seeds or bits, can be composed of a blend or mixture ofpowders from different vegetables, other foods, flavorings, and otheredible materials. Such other foods include cheese, pasta, milk, sugar,oil or fat, such as lard, butter, coconut fat, or olive oil, honey andnuts, for example, filberts, walnuts, pecans, cashews, coconut, andBrazil nuts. Flavorings include curry, chili powder, soya sauce or othersoya derivatives, salt, vanilla, ginger, pepper, thyme, saffron, sage,cinnamon, cloves, garlic, onion, and origanum Salt should be usedsparingly because any appreciable amount of salt will detract from thecohesion promotion of algin when used as a binder.

It is preferred that the kernels or bits be synthesized from powderhaving particles small enough to pass through a No. 10 U.S. standardmesh screen but which would be retained on a No. 300 U.S. standard meshscreen, preferably being predominantly about 100 mesh.

In this description, "reconstituted" is used to designate kernelscomposed essentially, if not entirely, of powder from one specific typeof grain seed or pulse seed of a shape very similar to, if not identicalto, the shape of the corresponding whole natural seeds, whereas the term"synthesized" is used as generic to reconstituted kernels and also tobits of other foods or special combinations resulting from a mixture ofpowders of different seeds and/or other vegetable and/or food componentsand may or may not be of a shape similar to the shape of some naturalseed. The term "bits" is used generically to cover kernels, cubic orcylindrical pellets, flakes and morsels of other shapes synthesized frompowder.

Moreover, "synthesized" is applied to powder bits having a substantialamount of spices, flavoring, medicaments, or pharmacological food mixedin with one or more varieties of vegetable components. The proportionsof components in such special combination synthesized bits may be suchas to provide in a single powder food product proper proportions ofvegetable ingredients to sustain life such as may be used for a completeobesity control diet or a diabetic diet.

The process of producing powder bits includes crushing, includinggrinding, or comminuting selected cereal seeds, legume or pulse seeds,or other vegetable material to a powder such as meal or flour, making aliquid binder such as a batter or a paste, fixing such liquid binderwith the vegetable powder to form a doughy material of consistencysuitable for extruding, extruding such doughy material through dies toform strings, severing such strings into kernels or other bits, andtreating such kernels or other bits with a binder-setting agent such asa calcium salt adequate to set the binder incorporated in the kernels orother bits and drying the bits. Preferably the doughy material isextruded twice to increase the density and homogeneity of the strings.The powder bits thus produced can be reconstituted kernels of the typehaving a shape resembling the shape of the seeds of a particular grainor pulse from which the vegetable powder for making the kernels came,such as kernels shaped like rice grains made from rice powder, orkernels shaped like beans made from bean powder, for example.

Instead of being extruded, the kernels or bits can be synthesized in theform of rice kernels or other shapes by being formed in a die. The bitscan be treated with a liquid binder incorporating low viscosity alginand fat, such as by being sprayed with such a binder while bits aremoving across a vibrating table or moving as a fluid bed. Subsequently,the bits can be similarly sprayed with a solution of binder-settingagent and air dried.

The liquid binder mixed with the powder from which the bits are madeprovides a cohesive powder mixture forming bits that will retain theirshape well despite wide variations in moisture content and temperature.

The binding material for the cohesive powder preferably is an algin suchas sodium alginate. The algin can be of any viscosity including the lowviscosity type from 1/10th to 1 poise and the high viscosity type from 8to 20 poises. If the algin is of the low viscosity type, the liquidbinder may be principally water, containing 0.1 percent to 20 percent byweight of algin, preferably 5 percent to 11 percent. If high viscosityalgin is used in the binder, the water may contain from 0.01 percent to12 percent of algin by weight, preferably 0.5 percent to 6 percent.

Alternatively, the binder material may be chitin material such aschitosan, chitosamine, chitose, or other chitin derivative form fungiand/or crustacean shells.

Whatever type or types of binding material are utilized in the liquidbinder, the total amount of binding material should be within the rangeof 0.01 to 20 percent of the water by weight.

In producing synthesized bits, whether reconstituted kernels of a singletype of grain or pulse or other bits of a special composite type, theliquid binder can be mixed with the powdered material of the seed,whether grain, pulse, or other food, to make a cohesive powder dough ofsoft consistency suitable for extruding in proportions of 2 to 4 timesas much bit-forming powder as liquid binder by volume, preferably about3 times as much.

For making rice kernels, rice powder and liquid binder may be extrudedby a press type of extruder such as that disclosed, for example, inGorozpe U.S. Pat. Nos. 2,914,005 and 3,071,471, or in Harrow et al. U.S.Pat. No. 4,325,976.

In carrying out the present invention, the extruded synthesized kernelsfall from the extruder into a body of boiling water containingbinder-setting or binder-gelling material which preferably is awater-soluble calcium salt, such as calcium chloride CaCl₂ or calciumlactate (CH₃ CHOHCOO)₂ Ca.5H₂ O, and preferably a combination of thesetwo chemicals; but, other water-soluble calcium salts could be usedinstead such as those more fully identified in the aforesaid RelatedApplications.

The preferred setting agent is composed of calcium lactate, 62.5percent, and calcium chloride, 37.5 percent, by weight. The amount ofcalcium salt may be within the range of 0.01 to 20 percent of the groundvegetable material by weight, preferably about 12 percent. Suchsolution, when sprayed onto the kernels or bits, sets or gels the binderso as to form a cohesive powder for producing firm, coherent, stabilizedbits. If the kernels or bits are deposited in a setting bath of hot,preferably boiling, aqueous solution, such solution should be somewhatacidic, such as having a pH of 4 to 6, to keep the calcium in solution.Acids such as lactic acid or adipic acid can be used to produce suchacidity.

If it should be desired to retard or prolong the effect of the settingor gelling agent, sodium carbonate Na₂ CO₃, sodium citrate Na₃ C₆ H₅ O₇,disodium phosphate Na₂ HPO₄, trisodium phosphate Na₃ PO₄, sodiumhexametaphosphate (NaPO₃)₆, tetrasodium pyrophosphate Na₄ P₂ O₇, sodiumpolyphosphate Na_(a+2) P_(a) O_(ea+1), or sodium tripolyphosphate Na₅ P₃O₁₀ in an amount of 0.01 percent to 20 percent by weight can be includedin the liquid binder.

Another procedure for deferring or extending the setting or gellingaction of calcium is to utilize calcium carbonate or calcium sulfate asthe source of calcium and restrict the access of acid such as aceticacid, adipic acid, citric acid, fumaric acid, gluconic acid, glutaricacid, lactic acid, malic acid, succinic acid, or tartaric acid or dgluconolactone C₆ H₁₀ O₆ to react with the substantially insolublecalcium salt for producing soluble calcium salt slowly.

If chitin material is used for the liquid binder, sulfuric acid orphosphoric acid or calcium ions or magnesium ions will set or gel thebinder.

In carrying out the present invention in accordance with the preferredembodiment thereof, kernels discharged from the extruder are preferablydeposited into boiling water and cooked for a period of on the order offrom 3 to 20 minutes so as to heat--and, preferably, fullygelatinize--the starch contained in the product and to expand thekernels. Such boiling water can contain the binder-setting agent. Thekernels are then removed from the boiling water, rinsed, drained, andconditioned for storage. Such conditioning preferably takes the form ofretrograding the expanded kernels so as to stabilize and solidify thekernels in their expanded state. This can be accomplished by freezingthe kernels, rapid monetary surface heating at a temperature rangingfrom about 155° F. to about 185° F. or, alternatively, by the use ofchemical additives such, for example, as alcohol; or mechanically bypermitting the product to sit in chilled water for extended periods oftime and/or by canning the product without excess moisture. Followingretrograding, and in those instances other than a canning process, theproduct is dried to reduce its moisture content, preferably to the 9.5to 10.5 percent level identified above as products with a moisturecontent in that range have an optimum combination shelf life andstructural range. However, as was also pointed out above, and is shownhereinafter, products with moisture levels as high as 12 percent and aslow as 9 percent may also prove to be acceptable.

A representative process for making a quick-cooking, reconstituted ricegrain product capable of rehydrating in one minute is described in thefollowing example.

EXAMPLE I Formable Dough

7,500 grams of rice flour milled from whole and broken grains of ricewere mixed with 127.5 grams of low viscosity sodium alginate dry powderKelco Gel LV, 1 25 grams of peanut oil used as a lubricant, 25 grams oflecithin used as an antioxidant, and 65.6 grams of dry albumin. Theforegoing ingredients were thoroughly blended in a vertical dough mixerfor 10 minutes. 2,250 grams of water was then added to the floor mixtureand remixed in the vertical dough mixer for 5 minutes, thus forming adoughy material suitable for extrusion.

Extrusion

The doughy material was then extruded through a pressure extruding presswith a standard Risso or rice-shaped die and cut at intervals so as toform rice-like kernels.

Gelatinization

Following extrusion, the reconstituted rice kernels were dropped into abody of boiling water containing 0.6 grams of calcium chloride and 1.0grams of calcium lactate per 400 grams of water. The reconstituted ricekernels were then cooked for approximately 9 minutes, or untilcompletely gelatinized--complete gelatinization has generally been foundto occur within about 8 to 10 minutes. The calcium salts served as agelling agent for the alginate.

Rinsing/Cooling

The gelatinized, reconstituted rice kernels were then drained andthoroughly rinsed in cool water until all excess setting agent had beenremoved and the kernels had been cooled to approximately roomtemperature.

Retrograding

The cooled, reconstituted rice kernels were then retrograded, orstabilized, and solidified in their expanded state by depositing in afreezer and permitting the kernels to be thoroughly frozen.

Drying

The frozen, reconstituted rice kernels were then dried on a heatedforced-air dryer at 120° F. for approximately 7 hours, or until thereconstituted rice kernels reached a 12 percent by weight moisturecontent--6 to 8 hours drying appears to be desirable. Utilizing thisrepresentative process the resulting rice kernels were found to becompletely rehydratable and edible within one minute of the addition ofan edible liquid such, for example, as hot or cold water or milk.

The foregoing experiment was repeated using both glutinous and longgrain rice without observing any appreciable difference in therehydration characteristics of the final product. It has been found thatfull gelatinization can be attained in other ways such, for example, asby steaming and/or microwaving. The setting agent can be applied to theproduct either before, during, or after gelatinization, for example, byspraying. Moreover, it has been found that the gelatinized,reconstituted rice kernels can be retrograded in other completelyconventional manners such as by the use of chemical additives such, forexample, as alcohol. Alternatively, the product can be retrograded byrapid momentary surface heating at a temperature ranging from about 155°F. to about 185° F., or by sitting in chilled water for extended periodsof time, or by canning the product without excess moisture. In eachinstance, the product is retrograded by permitting the starch toprecipitate and assume a solid form. Other methods of drying may beemployed to expedite or slow the drying process such as by utilizing amicrowave oven or a cool air drying process.

Flavoring, nutrients, fortifying substances and/or color can be added tothe vegetable meal or flour and binder liquid mix dough before beingextruded; and, such additions will permeate the dough thoroughly anduniformly. Such uniform permeation will persist in the synthesized bitsinstead of being applied to the powder bits as a coating. For example,20 percent to 35 percent of the dough mix by volume could be cheese, orto 5 percent, preferably 2 percent, of the dough by volume could be oilor fat. Other types of additives can be included in proportions from 5percent to 30 percent of the dough by volume, depending on theingredients used and the color or flavor desired. Flavors can be addedin an amount from 0.01 percent to 20 percent. Other food products whichcan be added in an amount up to 50 percent by volume include coconut,albumin such as egg, milk, and sugar. Also, 3 percent to 10 percent ofmonosodium glutamate by volume, preferably 6 percent, can be included toenhance the flavor of food ingredients other than rice.

If the powder kernel product being produced is rice or predominantlyrice, it is desirable for at least some albumin to be used becausealbumin restores a strong natural flavor to the rice. The albumin may bein the form of fresh or dried whole egg albumin. The amount of albuminused should be equal to percent to 20 percent, preferably 121/2 percentof the amount of water in the fluid binder by weight, which albumin canbe supplied at any stage during the kernel-forming process.

Vitamins, minerals, proteins, and/or amino acids can be added to variousgrain seeds and/or pulse seeds and/or other vegetable material inproducing the synthesized powder bits, especially for deprived people.The powder bits are substantially homogeneous and can constitute acomplete food complex incorporating properly balanced proportions ofcarbohydrate provided by the grain or pulses, protein, fat and/or oil.

In some instances, discretion must be used in selecting materials to beused by the body for producing proteins for incorporation in thesynthesized bits of the present invention. Proteins are peptides made upof two or more amino acids covalently bound in an amide linkage. Thus, apeptide is a chain of amino acid residues. All amino acids containnitrogen, and sometimes the body has and oversupply of nitrogen. In suchcases, instead of using amino acids as such, amino acid analogues fromwhich nitrogen has been completely or principally removed can beutilized. Suitable keto- and hydroxy-analogues which are free ofnitrogen corresponding to essential and beneficial amino acids can beused in place of the corresponding amino acids themselves. In suchinstances, the analogue will combine with the excess nitrogen of thebody to serve the dual function of enabling the body to produce proteinsand of removing some of the nitrogen from undesirable forms in the body.Such amino acids and their corresponding ketoanalogues andhydroxy-analogues are listed below.

    ______________________________________                                        Amino Acid Keto-analogue  Hydroxy-analogue                                    ______________________________________                                        ESSENTIAL AMINO ACIDS AND ANALOGUES                                           L-leucine  a-ketoisocaproic                                                              acid                                                               L-valine   a-ketoisovaleric                                                              acid                                                               L-isoleucine                                                                             (R,S)-a-keto-b-                                                               methylvaleric acid                                                 L-lysine                                                                      L-phenylalanine                                                                          phenylpyruvic acid                                                                           L-phenyllactic                                                                acid                                                L-threonine                                                                   L-methionine                                                                             a-keto-g-methiol-                                                                            (D,L)-a-hydroxy-                                               butyric acid   g-methiol-                                                                    butyric acid                                        L-tryptophan                                                                             indolepyruvic acid                                                                           indolelactic acid                                   BENEFICIAL AMINO ACIDS AND ANALOGUES                                          L-histidine                                                                              imidazolepyruvic                                                                             imidazolelactic                                                acid           acid                                                L-tyrosine P-hydroxyphenyl-                                                                             L-p-hydroxyphenyl-                                             pyruvic acid   lactic acid                                         L-cystine  BB'-dithiopyruvic                                                                            L-BB'-dithiodi-                                                acid           lactic acid                                         L-cysteine B-mercaptopyruvic                                                                            L-B-mercaptolactic                                             acid           acid                                                L-arginine                                                                    L-ornithine                                                                   ______________________________________                                    

Any of these amino acid and analogue structures in any combination andin appropriate quantities can be mixed into the powder material fromwhich the bits are synthesized in accordance with the present invention.

For people with excessive nitrogen or ammonia in the body, such as thosesuffering from hyperammonemia and portal systemic encephalopathy, theamino acids ornithine and arginine may be incorporated in the bits.

By incorporating a proper type and proportion of amino acids or theiranalogues in the powder material from which the powder bits of thepresent invention are synthesized, a properly balanced diet is assuredsimply from consumption of the bits of the present invention. To make acomplete food complex, an appropriate amount of oil and/or fat can beincorporated in the material used for the preparation of the bits.

Rice, corn, millet, wheat, and potatoes, for example, are excellentsources of carbohydrate, particularly for reducing diet or diabetic dietpurposes or for patients with hypoglycemia or hyperglycemia. Digestionof rice requires considerable time so that the carbohydrate is convertedinto sugar usable by the body over a period of several hours instead ofbeing available to the bloodstream quickly, such as in a period of lessthan an hour, as is the case with sugar or compounds readily convertedinto sugar by the body. Digestion of carbohydrate from corn or potatoescan be retarded by providing such food ingredients in the form ofsynthesized kernels. By associating protein, amino acid or amino acidanalogue and, if desired, oil and/or fat intimately with carbohydrate,all of the components become available for body building over anextended period of time instead of quickly. Such result can be achievedby incorporating the amino acid or analogue with powdered rice and, ifdesired, with an appropriate amount of oil or fat in the dough fromwhich the synthesized rice grains are extruded.

A representative extrudible dough could contain the followingingredients by weight in addition to the binder and flavoring, if any:

    ______________________________________                                        carbohydrate        25% to 99%                                                protein             1% to 75%                                                 oil or fat          up to 50%                                                 ______________________________________                                    

A preferred formula would have the following proportions of ingredientsby weight:

    ______________________________________                                               carbohydrate   75%                                                            protein        20%                                                            fat            5%                                                             TOTAL          100%                                                    ______________________________________                                    

Because each powder bit provides a complete balanced food in itself, adiet supplying any desired number of calories can be specified by simplyprescribing the proper quantity of synthesized rice.

For an adult of average size, Van Nostrand's Scientific Encyclopedia,Sixth Edition. states on page 2339, at column 1, under the definition ofPROTEIN that the daily requirement is 70-80 grams of protein. Actually,the bodily requirement depends on the size of the person, and it isperhaps more accurate to state that the daily bodily requirement forprotein is 0.7-0.8 grams of protein per kilogram of body weight.

Thus, for example, if a low fat diet containing 2,400 calories per daywere desired, the amount of synthesized rice to be eaten during the daycould be 590 grams, containing 560 grams of carbohydrate, 25 grams ofprotein, and 5 grams of fat. A higher fat diet providing 2,400 caloriescould be 520 grams of synthesized rice, containing 400 grams ofcarbohydrate, 70 grams of protein, and 50 grams of fat.

Amino acids and their analogues have very unpleasant tastes; and,consequently, it may be desirable to add pleasant flavoring materials tothe powder kernels such as curry, coconut, or chili powder, as suggestedabove, where amino acids or their analogues are incorporated in thekernels. The powder kernel grain or pulse product would, however, beavailable in a form which was familiar and to which deprived people areaccustomed. Moreover, such powder kernel product would be particularlybeneficial because it can be prepared for consumption quickly and withminimal, if any, energy requirements.

Apparatus

Referring to FIG. 1, there has been shown an exemplary apparatussuitable for performing certain of the foregoing steps. Thus, as hereshown, the apparatus includes a mixer 1 which may, for example, be ofthe helical screw type, to which mixer can be supplied powdered grainseed, such as rice flour, from a storage hopper 2 and binder, such asaqueous algin batter, from a storage hopper 3. Such algin batter isproduced by mixing algin such as sodium alginate with water in acontainer 4. The mixing can be accomplished by a motor-driven impeller5. The algin batter is pumped from the mixing container 4 to the storagehopper 3 by a suitable pump 6 which can be a diaphragm pump or animpeller pump. As described above, one or more types of vegetable powderin addition to the principal grain flour supplied from the storagehopper 2 can be supplied to the mixer 1. Such additional vegetablepowder could, for example, be pulse powder, such as bean powder, orother vegetable powder, such as corn meal. Such an additional vegetablepowder ingredient can be supplied to the mixer 1 from the storage hopper7.

The mixer may contain a helical screw rotated by the motor 8 to servethe dual purpose of mixing the ingredients in the mixer and conveyingthe resultant mixture to one end of the mixer for discharge through adischarge spout 9 into the inlet conduit 10 of a further helical screwmixer 11, the screw of which is driven by a motor 12. This mixer servesthe dual purpose of further mixing the ingredients supplied to the mixerand of feeding the mixture to an extruder 13 at the end of the mixeropposite the motor 12. Such extruder is rotated by a motor 14 andeffects both shaping of kernels or bits and cutting them to length so asto resemble a natural kernel of some particular grain or pulse or a bitof predetermined shape. The extruder 13 may be a Risso die extruder.

As shown in FIG. 1, the kernels or bits extruded from the extruder 13fall on the tray 15 of a harmonic conveyor 16 such as disclosed in CoxU.S. Pat. No. 3,817,370. The kernels or bits on this conveyor can besprayed with setting agent for setting the binder. Such setting agentmay be stored in a storage tank 17 from which the setting agent can bedispensed through a conduit 18 and a spray nozzle 19 that will spray thesetting liquid solution or suspension onto the kernels or other bitsreceived on the tray 15.

Alternatively, in the practice of the present invention the kernels orbits extruded from the extruder 13 may be deposited into a tank, orother container, of boiling water (not shown) which preferably containsthe setting agent. In such a system, after the kernels or bits are fullygelatinized--a process which generally takes from 8 to 10 minutesresidence time in the boiling water, but which can, in some instances,vary from 3 to 20 minutes--the kernels or bits are removed from theboiling water, drained and rinsed so as to cool the kernels or bits andremove any excess setting agent therefrom. The thus drained, rinsed, andcooled kernels or bits are then retrograded in their expanded state by,for example, freezing in a conventional freezer, rapid momentary surfaceheating at a temperature ranging from about 155° F. to about 185° F. or,alternatively, by completely conventional chemical or mechanical meansas previously described. Finally, the product is dried in any suitableor conventional fashion so as to reduce its moisture content to on theorder of from 10% to 13% moisture by weight.

However, where an apparatus such as shown in FIG. 1 is employed, thekernels or bits exiting from the extruder and deposited on the tray 15may be moved along the tray 15 by oscillating the latter until thematerial thereon spills off its right end as viewed in the drawing ontothe tray 20 of the next harmonic conveyor section 21. Additional settingagent supplied through a conduit 22 from the setting agent storage tank17 may be sprayed onto the kernels or other bits on the tray 20 by thenozzle 23. Oscillation of the tray 20 will convey the material on it tothe right as viewed in the drawing until it spills off the right end ofsuch tray into the receiving hopper 24 of the helical screw conveyor 25driven by motor 26. As the kernel or other bit material is conveyedalong the conveyor 25, it can be subjected to jets of superheated steamsupplied by pipe 27 and discharged into the conveyor by nozzles 28 forthe purpose of cooking or gelatinizing the product. The amount of steamthus supplied can be controlled by adjusting valve 29; while the timeduring which the bits in conveyor 26 are subjected to the steam isdetermined by the speed of the motor 26 and the pitch and length of theconveyor helix.

The steam-treated bits are, as shown in FIG. 1, discharged from thedischarge end of conveyor 25 onto a reticulated belt conveyor 30. As thematerial is being transported by that belt, it can be subjected to astream of air supplied through the duct 31 to the plenum chamber 32beneath the belt, which air may be heated or unheated depending upon thespeed and length of the belt 30 and the amount of drying action which itis desirable to accomplish by the air. Of course, those skilled in theart will appreciate that where it is desired to retrograde the steamheated kernels or bits discharged from conveyor 25, such bits can, priorto deposit on conveyor 30, be frozen or chemically or mechanicallyretrograded in the manner previously described.

Finally, from the conveyor 30 the bits are either transported tosuitable storage facilities or they may be packaged immediately by beingdeposited into a hopper 33 located above packaging containers 34 on abelt 35. A measuring valve 36 can dispense from the hopper 33 a quantityof material just sufficient to fill a container or carton 34 as itpasses beneath or pauses beneath the hopper 33. Conventional automaticequipment can be provided for closing and sealing the cartons 34 afterthey have been filled with the bit product of the present invention.

The invention may be embodied in still other forms without departingfrom the spirit or essential characteristics of the invention. Thepresent embodiments are therefore to be considered in all respects asillustrative and not restrictive, the scope of the invention beingindicated by the appended claims rather than by the foregoingdescription; and all changes which come within the meaning and range ofequivalency of the claims are therefore intended to be embraced therein.

What is claimed is:
 1. A process for producing a food product which isadapted to be rendered edible merely by the addition of an edibleliquid, said method consisting essentially of the steps of:a. crushingor comminuting an edible seed, stalk, leaf, or root into a powder; b.mixing the powder with algin and an edible liquid to produce a formabledough; c. forming discrete synthesized bits or kernels from the dough;d. applying a setting agent to the formed discrete synthesized bits orkernels; e. heating the formed discrete synthesized bits or kernels; f.physically stabilizing the heated formed discrete synthesized bits orkernels; and g. so drying the stabilized, formed, discrete, synthesizedbits or kernels as to reduce the moisture content thereof to 9-12percent by weight.
 2. The process defined by claim 1 in which themoisture content of the stabilized bits on kernels is reduced to 9.5 to10.5 percent by weight.
 3. The process defined by claim 1 furtherincluding the step of so rinsing the heated discrete synthesized bits orkernels prior to stabilization as to remove any excess setting agent andto cool the bits or kernels.
 4. The process defined by claims 1, 2, or 3wherein the formed discrete synthesized bits or kernels are gelatinizedby depositing the same in boiling water for a period on the order ofapproximately 8 to 10 minutes.
 5. The process defined by claims 1 or 2wherein the formed discrete synthesized bits or kernels are gelatinizedand set by depositing the same in boiling water containing a metallicsalt for a period on the order of 8 to 10 minutes.
 6. The processdefined by claim 5 wherein the metallic salt comprises a calciumchloride.
 7. The process defined in claim 5 wherein the metallic saltcomprises a mixture of calcium chloride and calcium lactate.
 8. Theprocess defined by claim 1 wherein the setting agent comprises ametallic salt.
 9. The process defined by claims 1 or 2 wherein theformed discrete synthesized bits or kernels are physically stabilized byfreezing the bits or kernels.
 10. The process defined by claim 9 whereinat least some of the rice kernels are broken.
 11. The process defined byclaims 1 or 2 wherein the edible seed is rice.
 12. The process definedby claims 1 or 2 where the food product is fortified by uniformlydistributing throughout the formable dough at least one agent selectedfrom the group consisting of:a. vitamins; b. minerals; c. proteins; d.amino acids; e. fats; f. oils; g. medicaments; and h. flavorings.